Drive / Controls (DW)

Direct Warper Drive/Control System

The UKIL drive/process control system utilizes the latest in hardware and software technology to offer the best performance, most dependable service and easiest system to operate available. A color touchscreen is used to display operating conditions and initiate commands. The graphic program is specialized for direct warping machine operation with easy to understand symbols and illustrations. The software includes a machine control program running on the PC under Microsoft Windows 7 with a real time extension. Control software is IEC 61131-3 compliant, the operator interface utilizes Microsoft Visual Basic. The Ethercat communication is a fast, reliable, “state of the art” control system for the 21st century.

Drives

The UKIL Drive System uses Yaskawa A1000 high performance AC vector drives. Drive regulation is under the direction of the control program, which utilizes encoder feedback for speed control. Standard features include a 380mm LCD touchscreen with complete process control and drive integration, programmable creep, slow, and fast speeds, and complete motion control at all times. A graphical alarm system allows for quick identification of out of tolerance machine conditions and machine stop causes. Process stop causes are mill programmable on a style by style basis for tolerance level and length of acceptable out of tolerance conditions. The PC utilizes compact flash card technology rather than hard drives for more reliable service life. The system is rated for 50 Deg C ambient operation and comes with a 2Gb Compact Flash card containing all programs including the Windows 7 embedded operating system. Easy to copy for emergency backup, the Compact Flash technology is extremely reliable.

I/O and Controls

Process Control

The UKIL Process Control System with Touchscreen operator interface utilizes 21st century technology. The software includes a machine control program running on the PC under Microsoft Windows 7 with a real time extension. Control software is IEC 61131-3 compliant, which is a universal standard.

The operator interface utilizes Microsoft Visual Basic. When connected by Ethercat to the I/O and AC Vector drives, the result is a fast, reliable, “state of the art” control system for the 21st century.

Features include:

PC control system running Microsoft Windows 7 embedded

Operator Interface is MS Windows based

Ethercat distributed I/O system

AC Vector drives connected through Ethercat

Touchscreen operator functions, no keyboard or mouse

Large, easy to read 380mm color display

Ethernet (100mb) connection for host systems

Ethernet connection for remote troubleshooting and modifications

Modular I/O system for simple field replacement

3C Labeling on all electrical cabinets

2) communication cards, one for Equipment Manager, one for Product Manager

All operator screens will be either local language or graphics

Pressing the appropriate command pushbuttons on the display carries out operator functions. Pop up numeric and alphanumeric keypads appear on screen for easy entry of data when required. Process alarms and optional machine stopping levels are programmable on a style by style basis. All process faults may be selected for machine stop with a mill programmable length of stop activation. The temperature level and length of out of tolerance acceptance are mill determined.

Safety machine stops or drive faults are recorded for the last 10 faults and displayed on the screen. A set of Stop/Creep/Slow/Fast pushbuttons are located on the right side of the LCD Touchscreen for operator use. If the machine will not operate in any speed (creep/slow/fast), the pushbutton for that speed will display a red slash through it and pressing will show the reason it is inhibited.

I/O is the rugged and fast Ethercat I/O from Beckhoff. Virtually any type of I/O is available, direct strain gauge interface, current, voltage, relay, etc. Connection is through high quality Ethernet cable and connectors. The speed is 100Mb, allowing for 1000 digital I/O’s in 30us or 200 16 bit analog I/Os in 50us. I/O is distributed on the machine close to connecting points, reducing the length and complication of field wiring.